Process of making a resin-composite panel

Abstract

The invention relates to a method of fabricating a fiberglass-resin impregnated composite article which has a non porous surface formed by melting and curing a suitable polymeric film thereon. The process further involves coating an adhesive layer having a release sheet thereon over the non-porous melted polymer surface for bonding onto a substrate, and the invention further relates to the particular formed article and a process of forming an air-conditioning frame.

I claim: 
     
       1. A method of making an air conditioning frame having an insulating article thereon, comprising coating a resin impregnated, partially cured fiberglass batt on a first surface with a layer of compatible resin;   applying a porous non-woven polymeric sheet onto the coated resin layer to form an article;   forming and curing the article at elevated temperature and pressure wherein the polymeric sheet melts and forms a non-porous coating on the first surface of the cured article;   coating a layer of effective adhesive on the first surface having the non-porous coating;   bonding the article in a desired location to an air conditioning frame.   
     
     
       2. A method in accordance with claim 1 wherein the adhesive is a high solids content adhesive. 
     
     
       3. A method in accordance with claim 1 wherein the resin-fiberglass batt comprises about 13 to 20 wt % phenolic resin and has a density of about 2 to 18 lbs./ft 3 . 
     
     
       4. A method in accordance with claim 3 wherein the layer of compatible resin is a phenolic resin less than about 1/8 inch thick and has a viscosity insufficient for passing through the fiberglass batt before forming. 
     
     
       5. A method in accordance with claim 1 wherein the polymeric sheet is selected from non-woven polyesters, polyamides, acrylics and mixtures thereof. 
     
     
       6. A method in accordance with claim 1 wherein the forming temperature ranges from about 350° to 550° F. for a time of about 1 to 4 minutes. 
     
     
       7. A method in accordance with claim 1 wherein the article forms a substantially planar sheet having a thickness of about 1/8 to 1 inch. 
     
     
       8. A method according to claim 1 wherein the melted polymeric sheet bonds to the fibers of the fiberglass batt in the immediate surface area. 
     
     
       9. A method in accordance with claim 2 wherein the adhesive exhibits a solids content of 40-65 wt %. 
     
     
       10. A method in accordance with claim 8 wherein the adhesive comprises:   ______________________________________                                    
                  % BY WEIGHT                                             
______________________________________                                    
VM & P Napththa     2-3%                                                  
Toluene             2-3%                                                  
Antioxidant         0.1-0.5%                                              
C9 Hydrocarbon Resin                                                      
                    5-10%                                                 
C5/C9 Hydrocarbon Resin                                                   
                    5-10%                                                 
Zinc Rosinate       2-5%                                                  
Cellulosic Thickener                                                      
                    0.5-1.5%                                              
Aliphatic Oil       5-15%                                                 
Amorphous Silica    l0-15%                                                
Defoamer            0.1-0.5%                                              
Ammonium Hydroxide  0.05-0.15%                                            
Water               40-50%                                                
Styrene-Butadiene Latex                                                   
                    5-15%                                                 
Weight per gallon = 8.8 pounds                                            
Percent Non-Volatiles = 45.5%                                             
______________________________________                                    
     
     
     
       11. A method of making a resin impregnated fiberglass product, comprising impregnating flame attenuated glass fibers with a binder resin and forming the resulting mixture into a plurality cured resin impregnated fiberglass batt;   coating the fiberglass batt on a first surface with a layer of compatible resin   applying a porous, non-woven polymeric sheet onto the coated resin layer to form an article; forming and curing the article at elevated temperature and pressure wherein the polymeric sheet melts and forms a non-porous coating on the first surface of the cured article;   coating a layer of adhesive on the first surface having the non-porous coating;   applying a non-porous release sheet to the adhesive layer and curing the article at elevated temperature.